Toothbrush with Powered Head

ABSTRACT

A powered toothbrush includes a handle having a neck. A head is mounted to the neck and has a first surface and an opposed second surface. At least one fixed tuft block is mounted to the head in a fixed orientation and has a plurality of tooth cleaning elements extending outwardly away from the first surface. A movable tuft block is flexibly connected to each fixed tuft block and has a plurality of tooth cleaning elements extending outwardly away from the first surface. A drive assembly is operably connected to the movable tuft block to move the movable tuft block with respect to each fixed tuft block.

FIELD OF THE INVENTION

This invention relates generally to toothbrushes, and, in particular, toa toothbrush with a powered head having fixed and movable tuft blocks.

BACKGROUND OF THE INVENTION

A variety of toothbrush configurations exist that have stationary and/ormechanically-driven movable cleaning elements. These conventionaltoothbrushes are dedicated to tooth cleaning/polishing operations andtypically include a head portion directed to the cleaning/polishingoperations, and a handle portion. The head typically has a flat orslightly altered surface to which tooth cleaning elements are attached,or to which mechanically-driven movable carriers for the tooth cleaningelements are attached.

Conventional toothbrushes have tooth cleaning elements that extend froma rigid head. Teeth and guns by nature have a complex intricate contour.Due to the rigid nature of the attachment of the tooth cleaning elementsto the head of the toothbrush, the orientation of the tooth cleaningelements is not flexible and thus conventional toothbrushes do notprovide optimal cleaning of teeth and gums. Conventional toothbrushestherefore have great difficulty in contacting areas of the teeth locatedat a greater distance from the head, including interproximal spacesbetween teeth.

I would be desirable to provide a powered toothbrush that reduces orovercomes some or all of the difficulties inherent in prior knowndevices. Particular objects and advantages will be apparent to thoseskilled in the art, that is, those who are knowledgeable or experiencedin this field of technology, in view of the following disclosure of theinvention and detailed description of certain embodiments.

SUMMARY

The principles of the invention may be used to advantage to provide apowered toothbrush with a least one fixed tuft block and at least onemovable tuft block driven by a drive assembly. In accordance with afirst aspect, a powered toothbrush includes a handle having a neck. Ahead is mounted to the neck and has a first surface and an opposedsecond surface. At least one fixed tuft block is mounted to the head ina fixed orientation and has a plurality of tooth cleaning elementsextending outwardly away from the first surface. A movable tuft block isflexibly connected to each fixed tuft block and has a plurality of toothcleaning elements extending outwardly away from the first surface. Adrive assembly is operably connected to the movable tuft block to movethe movable tuft block with respect to each fixed tuft block

In accordance with another aspect, a powered toothbrush includes ahandle having a neck. A head is mounted to the neck and has a firstsurface and an opposed second surface. A first fixed tuft block ismounted to the head in a fixed orientation. A second fixed tuft block ismounted to the head in a fixed orientation and is spaced from the firsttuft block. A movable tuft block is flexibly connected to the firstfixed tuft block and the second fixed tuft block by an elastomericmember. A drive assembly is operably connected to the movable tuft blockto move the movable tuft block in an oscillating manner with respect tothe first and second fixed tuft blocks.

In accordance with a further aspect, a powered toothbrush includes ahandle having a neck. A head is mounted to the neck and has a firstsurface and an opposed second surface. A first fixed tuft block ismounted to a distal end of the head in a fixed orientation. A secondfixed tuft block is mounted to a proximate end of the head in a fixedorientation and spaced from the first tuft block. A movable tuft blockis flexibly connected to the first tuft block and the second tuft blockby an elastomeric membrane and has a base portion including a slot. Abattery is mounted inside the handle, and a motor is operably connectedto the batter. A drive shaft is rotatably driven by the motor and has anoffset portion that engages the slot in the movable tuft block to drivethe movable tuft block in an oscillating manner.

Substantial advantage is achieved by providing a powered toothbrush withat least one tuft block and at least one movable tuft block driven by adrive assembly. In particular, certain embodiments improve cleaning ofteeth and gums, and provide improved access to and contact with areas ofthe teeth located at a distance from the head, including interproximalspaces between the teeth.

These and additional features and advantages disclosed here will befurther understood from the following detailed disclosure of certainembodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial sectional bottom view of a toothbrush.

FIG. 2 is a sectional view of the head of the toothbrush of FIG. 1,taken along section line 2-2.

FIG. 3 is a sectional view of the head of the toothbrush of FIG. 1,taken along section line 3-3.

FIG. 4 is a sectional view of an alternative embodiment of the head ofthe toothbrush of FIG. 1, taken along section line 2-2.

FIG. 5 is a sectional view of another alternative embodiment of the headof the toothbrush of FIG. 1, taken along section line 2-2.

FIG. 6 is a sectional view of a further alternative embodiment of thehead of the toothbrush of FIG. 1, taken along section line 2-2.

FIG. 7 is a sectional view of a further alternative embodiment of thehead of the toothbrush of FIG. 1, taken along section line 2-2.

FIG. 8 is a perspective view of yet another alternative embodiment ofthe head of the toothbrush of FIG. 1.

FIG. 9 is a sectional view of another alternative embodiment of the headof the toothbrush of FIG. 1, taken along section line 2-2.

FIG. 10 is a sectional view of another further alternative embodiment ofthe head of the toothbrush of FIG. 1, taken along section line 2-2.

The figures referred to above are not drawn necessarily to scale andshould be understood to provide a representation of the invention,illustrative of the principles involved. Some features of the toothbrushwith a powered head depicted in the drawings have been enlarged ordistorted relative to others to facilitate explanation andunderstanding. The same reference numbers are used in the drawings forsimilar or identical components and features shown in variousalternative embodiments. Toothbrushes with a powered head as is closedherein would have configurations and components determined, in part, bythe intended application and environment in which they are used.

DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS

Referring to the drawings, in FIG. 1 a toothbrush 10 includes a handle12 at a first end of the toothbrush, a head 14 at a second end of thetoothbrush, and a rotatable shaft 16 extending from handle 12 to head14. Handle 12 provides compartments for holding a drive assembly 19including an electric motor 20 and a power source 21. In certainembodiments, power source 21 is formed of two batteries 22, and 24. Ashaft coupling 26 is arranged to grip one end of shaft 16 and allow theshaft to be pulled out for cleaning or replacement.

Head 14 may be replaceable, or it may be permanently attached to handle12. Head 14 includes a plurality of tooth cleaning elements on a firstsurface 18 thereof. As use herein, the term “tooth cleaning elements”includes any type of structure that is commonly used or is suitable foruse in providing oral health benefits (e.g., tooth cleaning, toothpolishing, tooth whitening, massaging, stimulating, etc.) by makingintimate contact with portions of the teeth and gums. Such toothcleaning elements include but are not limited to tufts of bristles thatcan be formed to have a number of different shapes and sizes, massageelements, and elastomeric cleaning members that can be formed to have anumber of different shapes and sizes, or a combination of both tufts ofbristles and elastomeric cleaning members. The tooth cleaning elementsmay be arranged on head 14 in any configuration.

In embodiments in which head 14 includes bristle tufts, the tufts may beformed with bristles of the same or different bristle material (such asnylon bristles, spiral bristles, rubber bristles, etc.) Moreover, whilethe tooth cleaning elements of head 14 may be arranged so that they aregenerally perpendicular to first surface 18 of head 14, some or all ofthe tooth cleaning elements may be angled at various angles with respectto the first surface 18. When first surface 18 includes bristle tufts,it is thereby possible to select the combination of bristlesconfigurations, bristle materials and bristle orientations to achievespecific intended results and operational characteristics, thusmaximizing and enhancing cleaning, tooth polishing, tooth whitening,massaging, and stimulation.

The tooth cleaning elements may be arranged by any conventional method.For example, the tooth cleaning elements may be stapled to head 14. Incertain embodiments, the tooth cleaning elements in the form of strandsor bristles can be attached via in-molded technology (IMT) methods thatgenerally require small cross-sections of material into which thestrands are permanently attached. The strands utilizing IMT methods maybe attached during formation of the handle 12 or during formation ofhead 14, which is the portion of toothbrush 10 to which the strands andother materials are attached.

In other embodiments, tooth cleaning elements in the form of strands orbristles may be attached via anchor free tufting (AFT). In the AFT brushmaking process, described in detail in U.S. Pat. No. 6,779,851, nylon isfed into a pre-molded plate that can be made from any thermoplastic orelastomer material or combination thereof. This nylon my be processedinto bristle tufts of various sizes and shapes. The non-use or proximalend of the nylon is heated and melted to retain the nylon in the brushhead when a reasonable pulling force is applied. This head plate maythen be ultrasonically welded to a pre-molded handle that has aperipheral wall or frame on which the head plate will rest and becomefused to the handle.

Head 14 includes a first fixed tuft block 28 at a distal end thereof,and a second fixed tuft block 30 spaced from first fixed tuft block 28at a proximal end of head 14. Each of first fixed tuft block 28 andsecond fixed tuft block 30 have a plurality of tooth cleaning elements32 projecting outwardly from first surface 18 thereof. As noted above,tooth cleaning elements 32 can be any type of tooth cleaning elementssuch as bristles, massage elements, and elastomeric fingers or walls.

A movable tuft block 34 having a plurality of tooth cleaning elements 32is positioned between first fixed tuft block 28 and second fixed tuftblock 30. Movable tuft block 34 is flexibly connected to first fixedtuft block 28 and second fixed tuft block 30, allowing relative movementof third tuft block 34 with respect to first and second fixed tuftblocks 28, 30. This movement, in turn, allows tooth cleaning elements 32of movable tuft block 34 to contact other areas of the teeth located ata greater distance from the head, including interproximal spaces betweenteeth.

In certain embodiments, movable tuft block 34 is flexibly connected tofirst fixed tuft block 28 and second fixed tuft block 30 by a flexiblemember. The flexible member may be formed of any flexible or moldablematerial including thermoplastic elastomer (TPE), thermoplastic urethane(TPU), rubber, or silicone, for example. The flexible member may be aflexible membrane 36, as seen in FIGS. 1-2. Flexible membrane 36 may beformed of an elastomeric material such as a soft thermoplastic elastomer(TPE), or a blend of polypropylene (PP) and soft TPE, for example. Othersuitable materials for flexible membrane 36 will become readily apparentto those skilled in the art, given the benefit of this disclosure. Thewidth and/or thickness of flexible membrane 36 such that its toothcleaning elements 32 are positioned to achieve their greatest cleaningpotential.

Movable tuft block 34 has a slot 38 formed therein as seen in FIGS. 2-3.In the illustrated embodiment, slot 38 is formed in tuft block baseportion 40 that extends form movable tuft block 34 toward an interior ofhead 14. Shaft 16 has a remote-most end 42 that is off-set from acentral longitudinal axis 44 of shaft 16. Remote-most end 42 extendsinto slot 38 of movable tuft block 34. When shaft 16 and drivinglyengages slot 38 to cause movable tuft block 34 to move with respect tofirst fixed tuft block 28 and second fixed tuft block 30. The width ofslot 38 may be generally the same as the diameter of remote-most end 42,as seen in FIG. 3, to leave minimum play; thus keeping noise to aminimum during use. Shaft 16 is preferably of unitary, that is,one-piece construction, and is formed of a single length of a thin rodand shaped as shown. However, it is possible to arrange for remote-mostend 42 to be separately formed or provided and fixed to a straight endpart of shaft 16.

As shown in the embodiment illustrated in FIGS. 2-3, movable tuft block34 is driven in a rocking manner laterally with respect to longitudinalaxis 44 of shaft 16. That is, movable tuft block 34 rotates inoscillating fashion in the direction of arrow A in a plane extendingsubstantially perpendicular to longitudinal axis 44 and first surface 18of head 14.

It is to be appreciated that movable tuft block 34 can be driven bydrive assembly 19 in many different directions and in different ways.For example, as seen in FIG. 4, remote-most end 42 may have a firstoffset portion 43 and a second offset portion 45 positioned 180° fromfirst offset portion 43 about longitudinal axis 44. Remote-most end 42is configured such that first offset portion 43 and second offsetportion 45 are positioned so as to alternatively engage the proximateand distal ends, respectively, of movable tuft block 34 as shaft 16rotates. This alternate engagement of the proximate and distal ends ofmovable tuft block 34 causes movable tuft block 34 to rotate inoscillating fashion in the direction of arrow B in a plane extendingalong longitudinal axis 44 of shaft 16 and substantially perpendicularto first surface 18 of head 14. It is to be appreciated that in certainembodiments, remote-most end 42 could be configured with a single offsetportion such that it strikes only one of the proximate and distal endsof movable tuft block 34 to produce oscillating movement of movable tuftblock 34.

In another embodiment, as illustrated in FIG. 5, shaft 16 is directlyconnected to movable tuft block 34 by way of base portion 40. Shaft 16is configured to move in reciprocating fashion along longitudinal axis44, thereby causing movable tuft block 34 to move along arrow C in aplane extending along longitudinal axis 44 of shaft 16 and substantiallyparallel to first surface 18 of head 14.

In certain embodiments, shaft 16 can be replaced with another drivemember. For example, as seen in FIG. 5, rather than shaft 16, a cable 16is secured to base portion 40. Thus, as cable 16 is pulled toward handle12, movable tuft block 34 moves with respect to first tuft block 28 andsecond tuft block 30. To cause an oscillating movement of movable tuftblock 34 in such an embodiment, the cable would be pulled and releasedin intermittent fashion at a desired frequency. In such an embodiment,the resiliency of flexible membrane 36 allows movable tuft block 34 toreturn to its natural steady state condition each time the tension isreleased from the cable.

Thus, it can be seen that movable tuft block 34 can be caused to bemoved with respect to first fixed tuft block 28 and second fixed tuftblock 30 in many different directions, and in many different ways. Theresiliency of flexible membrane 36 allows this relative movement betweenmovable tuft block 34 and first and second fixed tuft blocks 28, 30.Other suitable mechanisms and methods of moving movable tuft block 34will become readily apparent to those skilled in the art, given thebenefit of this disclosure.

In certain embodiments, more than one movable tuft block 34 can beprovided on head 14. For example, as seen in FIG. 6, two movable tuftblocks 34 are flexibly connected to first fixed tuft block 28 and secondfixed tuft block 30 by flexible membrane 36. It is to be appreciatedthat any number of movable movable tuft blocks 34 can be flexiblyconnected to first fixed tuft block 28 and second fixed tuft block 30.Similarly, it is to be appreciated that any number of fixed tuft blockscan be positioned on head 14. Thus, only one, or more than two, fixedtuft blocks on head 14 would also be considered to be within the scopeof the present invention.

In certain embodiments where two movable tuft blocks 34 are provided, asseen in FIG. 7, remote-most end 42 may have a first offset portion 43and a second offset portion 45 positioned 180° from first offset portion43 about longitudinal axis 44. Remote-most end 42 is configured suchthat first offset portion 43 extends through the slot 38 formed in theproximal movable tuft block 34 and second offset portion 45 extendsthrough the slot 38 formed in the distal movable tuft block 34. Thus, asshaft 16 rotates, the proximal and distal movable tuft blocks 34 arecaused to oscillate in opposite directions in a plane extendingsubstantially perpendicular to both longitudinal axis 44 of shaft 16 andfirst surface 18.

It is to be appreciated that in other embodiments, movable tuft block 34may be flexibly connected to first and second fixed tuft blocks 28, 30by a flexible member having a different configuration than flexiblemembrane 36. For example, as seen in FIG. 8, movable tuft block 34 isflexibly connected to first fixed tuft block 28 and second fixed tuftblock 30 by a plurality of flexible bridge members 46 with voids or gapsprovided between the separate bridge members. The flexible bridgemembers 46 may be formed of any suitable flexible material, such as thematerials described above with respect to flexible membrane 36, forexample. The width and/or thickness of bridge members 46 can be adjustedto vary the amount of force needed to move movable tuft block 34 suchthat its tooth cleaning elements 32 are positioned to achieve theirgreatest cleaning potential.

In certain embodiments, as shown in FIG. 9, head 14 may include a tissuecleanser 48 on a second surface 50 of head 14 opposite that of firstsurface 18. Tissue cleaner 48 may be formed of an elastomeric material,such as a biocompatible resilient material suitable for uses in an oralhygiene apparatus. To provide improved comfort as well as cleaningbenefits, the elastomeric material preferably has a hardness property inthe range of A8 to A25 Shore hardness. As an example, one embodiment ofan elastomeric material is styrene-ethylene/butylene-styrene blockcopolymer (SEBS) manufactured by GLS Corporation. It is to beappreciated that SEBS material from other manufacturers, or othermaterials within and outside the noted hardness range could be used.Suitable materials for tissue cleanser 48 will become readily apparentto those skilled in the art, given the benefit of this disclosure.

Tissue cleanser 48 may be configured with a plurality of tissue engagingelements 52, which may be formed as nubs. As used herein a “nub” isgenerally meant to include a column-like protrusion (without limitationto the cross-sectional shape of the protrusion) which is upstanding froma base surface. In a general sense, the nub, in the preferredconstruction, has a height that is greater than the width at the base ofthe nub (as measured in the longest direction). Nevertheless, nubs couldinclude projections wherein the widths and heights are roughly the sameor wherein the heights are somewhat smaller than the base widths.Moreover, in some circumstance (e.g., where the nub tapers to a tip orincludes a base portion that narrows to a smaller projection), the basewidth can be substantially larger than the height.

Nubs 52 are designed to significantly reduce a major source of badbreath in people and improve hygiene. Nubs 52 enable removal ofmicroflora and other debris from the tongue and other soft tissuesurfaces within the mouth. The tongue, in particular, is prone todevelop bacterial coatings that are known to harbor organisms and debristhat can contribute to bad breath. This microflora can be found in therecesses between the papillae on most of the tongue's upper surface aswell as along other soft tissue surfaces in the mouth. When engaged orotherwise pulled against a tongue surface, for example, nubs 52 providefor gentle engagement with the soft tissue while reaching downward intothe recesses of adjacent papillae of the tongue. The elastomericconstruction of nubs 52 also enables them to follow the natural contoursof the oral tissue surfaces, such as the tongue, cheeks, lips, and gumsof a user. Moreover, the soft nubs 52 are able to flex as needed totraverse and clean the soft tissue surfaces in the mouth along whichthey are moved.

In certain embodiments, as shown in FIG. 10, a sealing member 54 may beprovided about base portion 40, extending between head 14 and extensionmember 40 of movable tuft block 34. Sealing member 54 serves to reducethe chances of infiltration into drive assembly 19. Sealing member 54may be formed of a resilient material, such as rubber or any othersuitable flexible material.

In light of the foregoing disclosure of the invention and description ofvarious embodiments, those skilled in this area of technology willreadily understand that various modifications and adaptations can bemade without departing from the scope and spirit of the invention. Allsuch modifications and adaptations are intended to be covered by thefollowing claims.

1. A powered toothbrush comprising: a handle having a neck; a headmounted to the neck and having a first surface and an opposed secondsurface; at least one fixed tuft block mounted to the head in a fixedorientation and having a plurality of tooth cleaning elements extendingoutwardly away from the first surface; a movable tuft block flexiblyconnected to each fixed tuft block and having a plurality of toothcleaning elements extending outwardly away from the first surface; adrive assembly operably connected to the movable tuft block to move themovable tuft block with respect to each fixed tuft block.
 2. The poweredtoothbrush of claim 1, wherein the drive assembly moves the movable tuftblock in an oscillating manner.
 3. The powered toothbrush of claim 1,wherein the drive assembly moves the movable tuft block in anoscillating manner in a plane that extends substantially perpendicularto a longitudinal axis of the handle and to the first surface.
 4. Thepowered toothbrush of claim 1, wherein the drive assembly moves themovable tuft block in an oscillating manner in a plane that extendsalong a longitudinal axis of the handle and substantially perpendicularto the first surface.
 5. The powered toothbrush of claim 1, wherein thedrive assembly moves the movable tuft block in an oscillating manner ina plane that extends along a longitudinal axis of the handle andsubstantially parallel to the first surface.
 6. The powered toothbrushof claim 1, wherein the movable tuft block is secured to the first andsecond tuft blocks by a flexible member.
 7. The powered toothbrush ofclaim 1, wherein the flexible member is an elastomeric membrane.
 8. Thepowered toothbrush of claim 1, wherein the drive assembly comprises apower source, and a motor having a shaft with an offset portion.
 9. Thepowered toothbrush of claim 8, wherein the tuft block comprises a tuftblock base portion having a slot formed therein, the offset portionextending into the slot.
 10. The powered toothbrush of claim 9, furthercomprising a flexible seal member extending between the head and thetuft block base portion.
 11. The powered toothbrush of claim 1, furthercomprising at least one additional fixed tuft block mounted to the headin a fixed orientation.
 12. The powered toothbrush of claim 1, wherein afirst fixed tuft block is positioned at a distal end of the head and asecond fixed tuft block is positioned at a proximate end of the head,the movable tuft block being positioned between the first fixed tuftblock and the second fixed tuft block.
 13. The powered toothbrush ofclaim 1, further comprising at least one additional movable tuft blockflexibly connected to each fixed tuft block, the drive assembly operablyconnected to each additional movable tuft block flexibly to move theadditional movable tuft block with respect to each fixed tuft block. 14.The powered toothbrush of claim 1, wherein the movable tuft block isflexibly connected to each fixed tuft block by a plurality of flexiblebridge members.
 15. The powered toothbrush of claim 14, wherein theflexible bridge members are formed of an elastomeric material.
 16. Thepowered toothbrush of claim 1, further comprising a tissue cleanser onthe second surface of the head.
 17. The powered toothbrush of claim 16,wherein the tissue cleaner includes a plurality of projections.
 18. Thepowered toothbrush of claim 17, wherein the projections compriseelastomeric nubs.
 19. A powered toothbrush comprising: a handle having aneck; a head mounted to the neck and having a first surface and anopposed second surface; a first fixed tuft block mounted to the head ina fixed orientation; a second fixed tuft block mounted to the head in afixed orientation and spaced from the first fixed tuft block; a movabletuft block flexibly connected to the first fixed tuft block and thesecond fixed tuft block by an elastomeric member; a drive assemblyoperably connected to the movable tuft block to move the movable tuftblock in an oscillating manner with respect to the first and secondfixed tuft blocks.
 20. The powered toothbrush of claim 19, wherein thedrive assembly comprises a power source, and a motor having a shaft withan offset portion, and the tuft block comprises a tuft block baseportion having a slot formed therein, the offset portion extending intothe slot.
 21. A powered toothbrush comprising: a handle having a neck; ahead mounted to the neck and having a first surface and an opposedsecond surface. a first fixed tuft block mounted to a distal end of thehead in a fixed orientation; a second fixed tuft block mounted to aproximate end of the head in a fixed orientation and spaced from thefirst tuft block; a movable tuft block flexibly connected to the firsttuft block and the second tuft block by an elastomeric membrane andhaving a base portion including a slot; a battery mounted inside thehandle; a motor operably connected to the battery; a drive shaftrotatably driven by the motor and having an offset portion that engagesthe slot in the movable tuft block to drive the movable tuft block in anoscillating manner.